Mark II Water Meter With Model K2 Controller - Pfening · 2017-01-11 · PFENING Mark II Water...

Installation Instructions

and

Service Manual

Mark II Water Meter

With Model K2 Controller (No Automatic Blender)

THE FRED D. PFENING COMPANY

1075 W FIFTH AVE.

COLUMBUS, OHIO 43212

Phone: 614-294-5361

Fax: 614-294-1633

PFENING Mark II Water Meter With Model K2 Controller V1.06 MAY 2009

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TABLE OF CONTENTS

General .......................................................................................................................................... 3

Installation .................................................................................................................................... 3

Operation ...................................................................................................................................... 8

Batch, Total, & Rate Displays .................................................................................................... 11

Alarms ........................................................................................................................................... 12

Programming ................................................................................................................................ 13

Advanced Programming .............................................................................................................. 16

Calibration Mode .......................................................................................................................... 18

Maintenance Mode ....................................................................................................................... 20

Zero Crossing Parameter ............................................................................................................. 21

Troubleshooting ............................................................................................................................ 22

Tables ............................................................................................................................................. 24

Parts Lists & Drawings ................................................................................................................ 27


3

GENERAL

The Pfening Mark II is the most advanced and reliable flow meter available on the market today. The

meter itself has a rugged, precision cast bronze housing with a synthetic polymer metering chamber

with only two moving parts.

Water flows through the meter's strainer and into the metering chamber where it drives the piston,

which oscillates around the central hub. The piston rotates the drive dog and magnet. An electronic

Hall Effect switch detects the motion of the magnet and generates pulses which are sent to the Model

K2 Controller. Each pulse represents a fraction of a pound of water. The controller keeps a running

total of pounds of water and displays the total as a whole number. When the preset total is reached, the

controller automatically closes the flow solenoid valve, stopping the flow of water.

The Model K2 liquid meter controller is a microprocessor-based unit that uses the latest electronic

hardware and software developments to provide user-friendly, accurate, and reliable control. It uses

advanced logic to provide manual and pre-set setpoints, which are easy to access and adjust. The

Model K2 controller includes sophisticated control logic to provide fully automatic water temperature

control in conjunction with the optional Pfening Automatic Temperature Blender.

Manual temperature blender assemblies are also available for this flow meter. Manual temperature

blending is achieved with either a two-way or three-way manual blender. Each blender has a

thermometer and a bypass valve so that water can be run to set the temperature before water is run

through the meter to the mixer. A different service manual is provided with automatic blenders.

INSTALLATION

Install your new meter assembly in accordance with Figure 1, 2, or 3, whichever applies. Wire the

controller and solenoid valve in accordance with Figures 4 and 5. Mount the Model K2 Controller box

in a place convenient for the operator, avoiding excessively wet locations. The Model K2 controller

can be mounted remotely, up to 100’ from the water meter. Also avoid locations subject to vibration,

such as the side of a mixer. Also, observe the following information for any of these installations:

1. Use a receptacle (120 volt single phase) of the grounding type and ground properly before using

the meter.

2. Water is to flow through the meter and solenoid valve in one direction only. A cast arrow

indicates flow direction. Mount the meter and solenoid valve in a horizontal line with the head

of the meter and the head of the solenoid valve upright as shown in the figures.

3. A strainer with 30 mesh (.02” screens opening) ahead of the meter is recommended. This

protects the meter and solenoid valve from foreign particles. If a three-way blender is being

used, a separate strainer will not be necessary as this blender has a built in strainer.

4. If a blender is being used, place a check valve in each of the lower pressure water lines (usually

the hot water and/or ice water lines). This is to prevent water from the highest pressure line


4

backing up into the lower pressure lines. To secure accurate blending results, all water supplies

should be within 10 psi of the same pressure when the water is flowing through the meter.

Pressure regulators in each line or a booster pump on the lowest pressure line may be necessary

if there is a wide pressure differential between the lines. You can tell if you have balanced

pressure by checking the rate of water flow from each line individually through the meter.

When the rates are the same, the pressures are balanced.

5. The maximum static pressure to which the meter is to be exposed is 100 psi. The flow rate

should be not less than 100 lbs. of water per minute and not more than 200 lbs. per minute, (11

to 25 gals. per minute). Water temperature may be from 32 ºF to 150 ºF.

6. It is recommended that 1" pipelines be used before and after the meter. A larger size may be

necessary if the run is long or complicated by many valves or elbows. If the pressure drop is not

sufficient to restrict the flow to less than 200 lbs. of water per minute, a regulator must be

placed in the line ahead of the meter. If a blender is being used, it will be necessary to have a

regulator in each inlet line to the blender, which can produce in excess of 200 lbs. of water per

minute. A pressure drop restricting the flow to less than 100 lbs. of water per minute indicates

an inadequate pipe size. See Table 1, “Piping & Pressure Calculations,” further on in this

booklet, which shows how to estimate your pressure losses and flow rates before making the

installation.

FIG. 1 MARK II METER ONLY


5

FIG. 2 MARK II METER & 2-WAY MANUAL BLENDER

FIG. 3 MARK II WITH 3-WAY MANUAL BLENDER


6

FIG. 4 CABLE IDENTIFICATION


7

FIG

. 5 W

IRIN

G D

IAG

RA

M


8

OPERATION

The auto blender assembly is equipped with a Model K2 controller, which has been programmed and

calibrated at the factory. A non-volatile memory ensures that program settings will not be lost if power

is interrupted. The display has four lines of text; the top two lines usually display operating information

while the bottom two lines display operator instructions.

FIG. 6 KEYPAD AND DISPLAY

The controller settings may be changed by the operator. Figure 6 shows the operator keypad and

display. See pages 13-20 for programming and calibration procedures.


9

Powering Up the Controller

When the Model K2 controller is first powered up, the display will show:

PFENING K2 V1.01

MARKII: WATER-LB

The top line shows the software version and the second line shows a summary of the current

programming.

Running a Manual Batch

Once the autoblender assembly and Model K2 controller are installed and power is applied, then display

should appear as shown:

ACTUAL 0 LB

MANUAL 60 LB

Push START to run

The actual amount of the last batch is displayed on the top line. The second line shows the manual

setpoint. In this example the manual setpoint is 60 lbs. of water.

To program a batch amount, simply enter the amount using the number keys. If you make a mistake,

press CLEAR and start over. If you entered a setpoint of 125 LB, the display will look like this:

ACTUAL 0 LB

MANUAL 125 LB

Push ENTER to save,

CLEAR for old value.

Press ENTER when the amount is correct or press CLEAR to bring back the previous value. The unit

will automatically save after five seconds. After the setpoint is saved the display will appear as shown:

ACTUAL 0 LB

MANUAL 125 LB

Push START to run


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To run the batch, press START and the display will show:

ACTUAL 0 LB

MANUAL 125 LB

BATCH STARTED

Push STOP to abort

The actual amount of water delivered is shown on the top line. When the actual amount reaches the

preset amount, the flow solenoid valve will close.

Press START again to run additional batches of the same size.

Stopping a Batch

Press STOP at any time to stop a batch. If you stopped a batch at 66 lbs, the display would appear as

shown:

ACTUAL 66 LB

MANUAL 125 LB

BATCH STOPPED

Push START to run

Pressing START will restart the batch where it left off. Pressing CLEAR will reset it to zero.

Using the Presets

The controller will store up to five setpoints. Press the PRESET key to see SETPT1. Press PRESET

again to see SETPT2. Press PRESET a third time to see SETPT3, and so on. To run a batch using a

preset, simply press PRESET until the correct setpoint is shown. For example, if you want to run

SETPT2, which is 45 LB, the display would appear as shown:

ACTUAL 0 LB

SETPT2 45 LB

Push NO for new

Value, START to run

See below for directions about how to change the presets. After five seconds the display will revert to:

ACTUAL 0 LB

SETPT2 45 LB

Push START to run

To run the batch, press START.


11

Changing the Presets

To change the preset weight, press NO. The display will show:

ENTER AMOUNT

SETPT2 67 LB

Push ENTER to save,

CLEAR for old value.

Use the number keys to enter the desired water amount, then press ENTER. Press CLEAR to go back

to the old value. The unit will automatically save after five seconds.

BATCH, TOTAL, AND RATE DISPLAYS

To see the total number of batches ran, press TOTALS. The display will appear as shown:

BATCH COUNT

44 BATCH

Push CLEAR to reset

This display says that 44 batches have been run since the last time the count was reset to zero. The

display will revert back to the normal display in three seconds. To reset the batch count to zero, hold in

the CLEAR button for three seconds. The batch count will flash 3 times and then reset.

Press TOTALS a second time to see the total amount of liquid ran. The display will appear as shown:

TOTAL AMOUNT

1278 LBS

Push CLEAR to reset

This display says that 1278 lbs. of liquid have been run since the last time the count was reset to zero.

To reset the total amount, hold in the CLEAR button for three seconds. The total amount will flash 3

times and then reset.

To see the rate, at which liquid is flowing through the meter, press TOTALS while the liquid is flowing.

The display will appear as shown:

FLOW RATE

166 LB/MIN


12

This says that the rate of liquid flow is 166 lbs. per minute. This display will read zero if no liquid is

flowing.

ALARMS

If the START button is pressed, but the controller receives no count input for seven seconds, the

solenoid is automatically closed and the display shows:

NO FLOW DETECTED

SETPT2 45 LB

Automatic Shutoff

Push CLEAR to reset

This is intended to prevent overfilling of the mixer when the valve is open, but no pulses are reaching

the controller. Correct the problem before attempting to run. See the troubleshooting section on page

22. Press CLEAR to reset the alarm.

If the actual count of liquid goes over the setpoint amount, the display will show:

ACTUAL 52 LB

SETPT2 45 LB

**OVERFLOW detected*

Push CLEAR to reset

Press CLEAR to reset the alarm. The display will show the actual amount of liquid delivered.

The overflow alarm will also be shown when pulses reach the controller when none should. For

instance, if the shutoff valve is leaking and water is dribbling through the meter, the overflow alarm

will be shown. Correct the problem and press CLEAR to clear the alarm.

If someone attempts to enter a zero setpoint, the zero setpoint alarm will come up, as follows:

ACTUAL 0 LB

MANUAL 0 LB

ZERO SETPOINT ERROR

Enter setpoint value

Use the number keys to enter a setpoint.


13

PROGRAMMING

Current programming: Upon power-up, the controller screen looks like this for three seconds:

PFENING K2 V1.01

MARKII: WATER-LB

The upper line shows the software version number. The lower line shows a summary of the current

programming. In this example, the controller is programmed for a Mark II water meter, in lbs.

Controller programming: The controller has been programmed at the factory and reprogramming

should not be necessary. If you have a problem, work through the troubleshooting section on page 22

before changing the programming. If you suspect that the programming has been changed, the original

factory programming may be restored as described below.

Numeric code: To use this method, a six-digit number is created using Table 2 on page 25. Work

through this and write down the number. Then unplug the controller for 10 seconds, then hold in the 5

key, and plug the unit back in with the 5 key held in. The controller will show this:

Enter six digit

programming code:

0

Push ENTER when done

If you enter an invalid code, the screen will show:

CODE ERROR

Must be from 111111

to 433424. EXIT to

exit, CLEAR to retry

Program Mode

Programming is done through the keypad. To enter the program mode, first make sure the meter is

stopped (press STOP if necessary), then press the PROGRAM key. The display will show:

..PROGRAM MODE..

PASSWORD

To enter Program

Mode, enter PASSWORD


14

The password is 5354. Use the keyboard to enter the password. The numbers will not be displayed on

the screen. Press ENTER. If you enter the password wrong, it will ask you to try again. If you have

entered it correctly, the display will appear as shown:

..PROGRAM MODE..

PROGRAM UNIT

NO for choice,ENTER

to select, or EXIT

At this point you can continue into the program mode by pressing ENTER or else press NO for access

to the CALIBRATION MODE or MAINTENANCE MODE. Calibration and maintenance modes are

discussed on pages 18-20 respectively. Press ENTER to continue into the PROGRAM MODE.

..PROGRAM MODE..

SELECT UNITS LB

NO for choice,ENTER

to select, or EXIT

To leave the programming mode at any time, press EXIT. The controller will save any changes made

up to that point. To view the programming choices, press the NO key. In this case, the units can be LB

(pounds), KG (kilograms), LT (liters), or GA (gallons). When the correct units are displayed, press

ENTER to advance to the next step. The display will look like this.

..PROGRAM MODE..

SELECT DEC PT 000.0

NO for choice,ENTER

to select, or EXIT

Press NO to see the choices available, which is none, one, two, or three decimal places. Please note

that displaying more decimal places does not make the meter more accurate and may be misleading.

When the correct number of decimal point places is displayed, press ENTER to advance to the next

step. The display will look like this.

Note: If you want to go back, press PROGRAM to go back to the first step, press ENTER to go

forward.

..PROGRAM MODE..

SELECT LIQUID- WATER

NO for choice,ENTER

to select, or EXIT

Use the NO key to see the choices, which are water, oil, and sugar (liquid sugar). When one of these is

chosen, the controller will automatically adjust the scale factor for the density of the liquid being

metered. Press ENTER when the correct liquid is displayed. The display will go to the next step and

the display will look like this:


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..PROGRAM MODE..

NO FLOW ALARM - ON

NO for choice,ENTER

to select, or EXIT

Use the NO key to turn the no flow alarm on or off. In general, we recommend that it be ON at all

times. The no flow alarm shuts off the liquid flow if no pulses are being received at the controller when

the valve is open. Press ENTER to advance to the next step and the display will look like this:

..PROGRAM MODE..

TEMPERATURE OFF

NO for choice,ENTER

to select, or EXIT

There are three possible settings for the temperature control: ON, OFF, and DISPLAY ONLY. This

setting should be set to OFF, unless you have a RTD temperature probe, in which case, set this setting

to DISPLAY ONLY. If you have an automatic temperature blender please refer to the automatic

temperature blender manual. If DISPLAY ONLY was chosen the unit will show:

..PROGRAM MODE..

SELECT TEMP UNITS_F

NO for choice,ENTER

to select, or EXIT

The units may be ºF or ºC. Press NO to make changes and ENTER to choose. The display will look

like this:

..PROGRAM MODE..

END BASIC PROGRAM?

Push ENTER to end,

NO for Adv Program

This screen allows you to either complete the basic unit programming or enter the advanced

programming section. The basic unit programming is all that most users will need. The advanced

programming section allows you to manually change the numeric values in the program. This should

only be attempted by qualified personnel.

To complete the basic programming, press ENTER. The screen will look like this.

..PROGRAM MODE..

SELECT METER-MARK II

NO for choice,ENTER

to select, or EXIT


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Use the NO key to select which meter you have. A quick identification guide is:

Mark I has ¾” pipe connections and is natural brass finish

Mark II has 1” pipe connections and has a silver finish

Mark V has 1 ½” clamp connections and is stainless steel

HW (Hot Water) meter has clear plastic top.

Press ENTER when the display shows the correct meter. The controller will select the scale factor,

which is correct for your meter. The controller will save the data and after five seconds the display will

revert to the display that was present before entering the program mode.

ADVANCED PROGRAMMING

To enter the advanced programming mode, when the display shows:

..PROGRAM MODE..

END BASIC PROGRAM?

Push ENTER to end,

NO for Adv Progrom

Press NO and the display will change to:

..ADV PROGRAM MODE..

ADVANCED PROGRAM

ENTER for Adv Prog

EXIT to abort Prog

Press ENTER to enter the advanced programming mode. The display will look like this:


SCALER 0.12890

Key in a new value.

The number 0.12890 is an example only; it may be different for your meter. See Table 3 on page 26 for

factory programmed values.

The SCALER is the amount of liquid metered for each change of state of the pickup switch in the water

flow meter. The controller counts both the rise and fall of each pulse, so there are two changes of state

for each pulse. Use the numeric keys to enter the scaler you wish. The maximum value of the scaler is

99.99999. If you are calibrating a meter, read the Calibration section on page 18. If you make a

mistake, key in zeroes until the display is cleared, then start over. When the correct value is displayed,

press ENTER to advance to the next step. The display will show:


17


PREACT AUTO 0.520

NO for choice,ENTER

to select, or EXIT

The PREACT is the amount of liquid which passes through the valve between the time the coil is de-

energized and the when the valve actually closes. There are two methods available: a fixed value and

an automatic preact in which the controller continuously monitors the overshoot and uses 10% of the

overshoot to correct the preact for the next batch. Most users should choose the automatic preact. The

factory preact values are shown in Table 3 on page 26. To change the fixed preact, use the numeric

keys, then press ENTER.

To select the automatic preact, press NO then ENTER to advance to the next step. The display will

look like this:


NO OF ACTIVE SETPT 6

NO for choice,ENTER

to select, or EXIT

The number of active setpoints may be from one to six. Press NO to change the number. If set at one,

only the MANUAL setpoint is available. If set at two, the MANUAL setpoint plus 1 PRESET is

available, and so so on. When set at six, the MANUAL setpoint plus all five PRESETS are active.

This feature is provided so that if only some of the PRESETS are in use, the others may be turned off so

they do not confuse the operator. Press ENTER when the display shows the correct number of presets.

The display will show:

..PROGRAM MODE..

PROGRAM UNIT

NO for choice,ENTER

to select, or EXIT

If you are finished programming, press EXIT and the display will show:

SAVING

PROGRAM IN MEMORY

Please wait!

The controller saves the data and reverts to the previous display.


18

CALIBRATION MODE – AUTOMATIC CALIBRATION

Press the program button and after entering the PASSWORD (see page 14), the user may choose to

enter the CALIBRATION MODE. With the screen showing this:

..PROGRAM MODE..

PROGRAM UNIT

NO for choice,ENTER

to select, or EXIT

Press NO until the screen shows:

..PROGRAM MODE..

CALIBRATE UNIT

NO for choice,ENTER

to select, or EXIT

Press ENTER and the display will show:

..CALIBRATION MODE..

SCALER 0.12890

Push ENTER to cali-

brate, NO to skip.

The number 0.12890 is an example – your number may be different. Press ENTER to enter the

calibration mode and the unit will show:


AMOUNT 0

Enter test amount to

run and press ENTER

Ideally, the flow meter will be calibrated at approximately the batch size most commonly used. If this

is impractical, we suggest a minimum calibration amount of 100 lbs. A container large enough to hold

the batch amount and a scale for weighing it are required. Water weights 8.35 lbs/gal. For example, if

you entered 100 lbs and pressed ENTER, the display will show:


AMOUNT 100

Push START if catch

bucket in place.


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Press START and water will run until the test amount is metered out. The display will then show:


ACTUAL 0

Weigh test amt, key

in wt, press ENTER

If the 100 lb test batch actually weighs 102 lbs, key in 102 and the display will show:


ACTUAL 102

Weigh test amt, key

In Wt, press ENTER

Next, press ENTER and the controller will automatically calculate a new scaler and display as follows:


OLD SCALER 0.12890

NEW SCALER 0.13148

Push ENTER to accept

Press ENTER to accept the new scaler, NO to revert to the old value. Press EXIT to exit setup.

Manual Calibration

The meter is factory calibrated and should require no adjustments for many years. However, should

calibration be necessary, the following procedure may be followed:

1. Obtain a scale and a container capable of holding at least 100 lbs. of water.

2. Weigh the empty container and record the weight.

3. Set the meter for 100 lbs. and run the water into the container. Allow the hose to drain.

4. Weigh the container and water, then subtract out the weight of the container.

5. Calculate an adjustment factor:

Actual Weight of water = Factor

100 lbs.

i.e. If actual Weight of water is 102 lbs, then 102 lbs. = 1.02

100 lbs.

6. Go to the programming section on pages 13-17. Follow the instructions (including entering

advanced programming) and find the scaler.

7. Multiply the scaler by the factor found above.

New Scaler = Old Scaler x factor

i.e. If the old scaler is 0.12890 and the factor is 1.02, then:


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0.12890 x 1.02 = 0.13148

8. Enter the new scaler and press EXIT to return to the normal display.

9. Note: If the adjustment to the scaler is more than five percent, there is a serious problem with the

meter. See the “Not Metering Accurately” in the troubleshooting section on page 22.

MAINTENANCE MODE

After entering the PASSWORD (see page 14), the user may choose to enter the MAINTENANCE

MODE. With the screen showing this:

..PROGRAM MODE..

PROGRAM UNIT

NO for choice,ENTER

to select, or EXIT


..PROGRAM MODE..

MAINTENANCE MODE

NO for choice,ENTER

to select, or EXIT

Calibration is discussed on page 18. Press ENTER to continue into the MAINTENANCE MODE. The

screen will show:

----ACTUAL 0 LB

POT VOLTAGE 0.54

BLNDR POSITION 39

BLNDR SETTING=MANUAL

The displayed values are:

1. Top line: actual volume of liquid drawn.

2. Second line: position potentiometer voltage reading.

3. Third line: blender valve angular position.

4. Bottom line: blender valve setting – use NO to toggle between MANUAL, BLEND, HOT,

CITY and ICE.

(Note: Automatic blending unit is required for items 2 through 4. See automatic blender manual.)

Maintenance controls are provided to easily test the flow valve. Press START to open and STOP to

close.


21

ZERO CROSSING PARAMETER

After entering the PASSWORD (see page 14), the user may choose to change the zero crossing

parameter. With the screen showing this:

..PROGRAM MODE..

PROGRAM UNIT

NO for choice,ENTER

to select, or EXIT


..PROGRAM MODE..

MAINTENANCE MODE

NO for choice,ENTER

to select, or EXIT

Press ENTER to continue into the MAINTENANCE MODE. The screen will show:

----ACTUAL 0 LB

POT VOLTAGE 0.54

BLNDR POSITION 39

BLNDR SETTING=MANUAL

Press ENTER to continue to change the zero crossing parameter. The screen will show:

ZERO CROSSING

TIME CONSTANT 4

ENTER VALUE 1 to 8

In order to reduce wear on the relay contacts, the controller attempts to operate the relay as the AC

voltage crosses zero (hence “zero crossing”). In order to do that, it must de-energize the coil 1 to 8

milliseconds early. The default value is 8 ms, but can be changed if necessary.

If you receive a zero crossing error at the end of the draw, change the time constant up or down 2 ms. If

this does not correct the zero crossing problem, the circuit board my need to be replaced.

CAUTION: Changing this to an erroneous value may cause the unit to stop working.


22

TROUBLESHOOTING

Water runs, but there is no count:

Switch is loose: Open the top cover of the meter and make sure that the pick-up switch is tightly held

against the top of the meter casing by the retainer plate. Turn the retainer plate counter-clockwise to

tighten it down.

Switch wires loose or broken: Check that the wires from the controller to the switch are not broken or

loose.

Switch defective: To check for a defective switch, open the top cover of the meter and disconnect the

three wires. Touch the black and white wires together rapidly. The counter should count (the count

may be very erratic). This shows that the counter is working.

Another way to check switch operation is to remove the switch by turning the retainer plate clockwise.

Leave the wires hooked up. Find a small magnet (this must be a loose magnet, not one in a holder, such

as a screwdriver handle). Alternately touch the north and south poles of the magnet to the bottom

center of the aluminum switch housing. The controller will display 1 LB for about every eight touches

of the magnet.

If the switch appears to be defective, open up the controller and check the voltage between terminals 5

V and GND on the back of the controller. It should be 5 VDC. Next, check the voltage between

terminals 5V and FCNT. Take the magnet and touch the bottom of the switch, alternating the poles

with each touch. It should alternate between 0 and 4.5 VDC. If the switch is defective, install a new

one. See page 7 for wiring schematic.

Controller defective: If the controller does not count when the black and white wires are touched, check

the voltage between the red and black wires. It should be 5 VDC. If not, check the wires and check

that 5 VDC is present between terminals 5V and GND on the back of the controller. If voltage is

present, but the unit still does not count, touch a jumper wire between terminals 5V and FCNT. The

controller will display 1 LB for about every eight touches of the jumper. If the unit counts, the problem

is in the wiring, if not, the problem is in the controller. Replace the controller board. See page 7 for

wiring schematic.

Scale factor set near zero: If the meter has been re-calibrated in the field, it is possible for the scale

factor to be set very low, which will appear to not register. See page 13 for reprogramming.

Meter internals not moving: To check if the magnet inside the meter is turning when water is flowing,

remove the pickup switch by turning the retainer plate counter-clockwise. Get a paper clip and cut a ¼”

long piece of wire. Place this wire in the machined recess in the top of the meter housing where the

switch rests. The magnet inside will pull the wire into alignment with it. Now turn on the water. If the

magnet is turning, the wire will turn with it. If the wire is not turning, open the meter and determine

what is preventing rotation. Foreign matter in the meter is the most likely cause. If the meter internals

show considerable wear or scoring, replace the internals.


23

The unit is plugged in and power is on, but nothing happens:

Wiring: Check that all wires on the back of the controller board are firmly connected.

Power: Check that 120VAC power is present at terminals L1 and L2 on the back of the controller.

Fuse: Check that the fuse on the circuit board is not blown. If it is, replace it with 2.0A, 250V fuse.

Controller: If power is supplied to the controller and the fuse is good, but the display is dark or

meaningless, the controller board should be replaced.

Solenoid valve: Check to see that the solenoid valve is receiving power when the START button is

pushed. If it is getting power but does not open, check the solenoid valve coil. See page 29 for

solenoid valve assembly diagram.

Not metering accurately:

Scale factor changed: If the liquid amount is off proportionately the same amount each time, the scale

factor may have been changed. See the programming section on page 13.

Meter internals worn: If the scale factor is correct, but a proportional error of more than 5% is present,

the meter internal parts may be worn, broken, or improperly installed. Disassemble the meter and

inspect. Reassembly should be done on a workbench.

Meter internals heat distorted: The standard meter internals are limited to 150 degrees F operation. If

water hotter than this is passed through the meter, the internal parts may become distorted, which will

prevent proper operation. Distortion generally causes the meter to run slow, resulting in too much

water.

If distortion is suspected, disassemble the meter and remove the metering chamber. The cylindrical

sides of the metering chamber should be straight. If a straightedge shows them to be concave, replace

the metering chamber. See page 28 for meter assembly diagram.

Additionally, the meter internals should turn freely. A small amount of air blown in the rectangular

inlet on the side of the metering chamber should spin the internals, making a characteristic “wuk-wuk-

wuk” sound.

Water won’t shut off at setpoint:

Solenoid Valve: If the solenoid valve remains open when de-energized, it is stuck open (rapping it will

sometimes make it close). Disassemble the valve and clean all the parts. If this does not fix the

problem, install a new valve or rebuild the existing one.


24

Temperature setting on the Blender is too sensitive. Small setting changes cause big temperature

changes:

This is generally the result of unbalanced water pressure in the lines. Run the unit with ice water only

and check the rate in pounds per minute. Run the unit with city water only and check its rate. For good

blender control, these rates should be about the same. This may be done with hot water providing it

isn’t more than 150 degrees F.

Pressure unbalance generally can be corrected by running a large pipe on the lower pressure line back to

its source or in the case of ice water increasing the pump pressure. Regulators can also be used to

reduce the higher pressure line’s flow rates to match the lowest pressure line, but be sure that the

resulting pressure doesn’t reduce the flow rate to less than 100 lbs. per minute through the meter and

solenoid valve.

Display is Dim:

Over time the display may grow dim and hard to read. This is adjustable. Turn off the power and

remove the front cover. The adjustment is a multi-turn potentiometer located on the back of the board,

on the right side, about a quarter of the way down from the top. It is labeled “DISPL ADJ”. Turn

counterclockwise to brighten the display.

Zero Crossing Error:

This means that the unit is missing the zero crossing. The default value is 8 ms. See page 25 for

explanation and setting. In general, this must be set for 7 or 8 ms. Other values may cause the unit to

stop working.

Piping & Pressure Calculations:

This section will be helpful in determining the pipe size to use or the rate of water flow with a given

pipe size.

The pressure drop in the line may be estimated from the following:

Rate of Water Flow Pressure Drop – PSI

Lbs/min

Gals./min

Mark II

Meter

2 Way

Blender

3 Way

Blender

Cut-Off

Sol. Valve

¾” Pipe

Per Ft.

1” Pipe

Per Ft.

1 ¼” Pipe

Per Ft.

100 12 1.3 1.0 2.0 2 0.19 0.06 0.015

150 18 3.2 2.4 3.5 4 0.40 0.12 0.032

200 24 6.3 4.5 6.0 7 0.70 0.20 0.055

250 30 9.0 6.7 9.0 11 1.0 0.30 0.082


25

Approximate equivalent lengths in feet of pipe for various fittings:

Fitting Pipe Size

¾” 1” 1 ¼”

Ball Valve 2 2.5 3

Globe Valve 22 27 38

Elbow 2.2 2.7 3.6

Tee 4.5 5.7 7.5

Table 1 – Piping & Pressure Calculations

Table 2 – Numeric Code

(See Page 13 to understand how to use this feature.)

For example, if you have a Mark II water meter, with a 1 decimal point weight accuracy displayed in

pounds. The code that should be entered is 121222.

Temp. Units

1 = ºC

2 = ºF

Volume Units 1 = LB

2 = KG

3 = LT

4 = GAL

Liquid Type

1 = Water

2 = Oil

3 = Sugar

Decimal Point

1 = None

2 = One

3 = Two

Temp. Control

1 = Off

2 = Display Only

3 = Control On

Meter Types

1 = Mark I

2 = Mark II

3 = Mark V

4 = Hot Water


26

FACTORY DEFAULT VALUES

Mark II Meter (Water Only) Units Pounds Gallons Liters Kilograms

Preact 0.520 0.062 0.236 0.236

Decimal Point None None None None

Scaler 0.12890 0.01544 0.05845 0.05845

Alarm On On On On

(These values are subject to change without notice.)

Table 3 – Factory Default Values


27

FIG. 7 MODEL K2 ASSEMBLY


28

FIG. 8 MARK II METER ASSEMBLY


29

FIG.9 1” SOLENOID VALVE ASSEMBLY


30

FIG.10 1” SOLENOID VALVE ASSEMBLY

PARK

ER VALVE

USED PRIOR

TO

MAY, 2009


31

FIG.11 1” MANUAL 2-WAY BLENDER ASSEMBLY


32

FIG.12 1” MANUAL 3-WAY BLENDER ASSEMBLY

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